RETURN TO MAIN MENU

IM10072
OUTBACK 185
May, 2012
™

For use with machines having Code Numbers: 11731

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

OPERATOR S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.216.481.8100 For Service in U.S. and Canada: Call 1.888.935.3877
FAX: 1.216.486.1751 WEB SITE: lincolnelectric.com For Non-U.S. Service: Email [email protected]
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

®
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and within applicable OSHA PEL and
should be as close as possible to the area being welded. ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
3.e. Ground the work or metal to be welded to a good electrical stances, outdoors, a respirator may be required.
(earth) ground. Additional precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected
damaged insulation. by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
3.g. Never dip the electrode in water for cooling. cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.h. Never simultaneously touch electrically “hot” parts of periodically thereafter to be certain it is within applicable
electrode holders connected to two welders because voltage OSHA PEL and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock. form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

®
iii iii
SAFETY
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturer s
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturer s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

®
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instructions zones où l on pique le laitier.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 6. Eloigner les matériaux inflammables ou les recouvrir afin de
antes: prévenir tout risque d incendie dû aux étincelles.

Sûreté Pour Soudage A L Arc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d incendie.
a. Les circuits à l électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. S assurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail qu il est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou d autres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien s isoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques d incendie ou d echauffement des chaines et des
les positions assis ou couché pour lesquelles une grande câbles jusqu à ce qu ils se rompent.
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble 9. Assurer une ventilation suffisante dans la zone de soudage.
de soudage et la machine à souder en bon et sûr état Ceci est particuliérement important pour le soudage de tôles
defonctionnement. galvanisées plombées, ou cadmiées ou tout autre métal qui
d.Ne jamais plonger le porte-électrode dans l eau pour le produit des fumeés toxiques.
refroidir.
e. Ne jamais toucher simultanément les parties sous tension 10. Ne pas souder en présence de vapeurs de chlore provenant
des porte-électrodes connectés à deux machines à souder d opérations de dégraissage, nettoyage ou pistolage. La
parce que la tension entre les deux pinces peut être le chaleur ou les rayons de l arc peuvent réagir avec les vapeurs
total de la tension à vide des deux machines. du solvant pour produire du phosgéne (gas fortement toxique)
f. Si on utilise la machine à souder comme une source de ou autres produits irritants.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s applicuent aussi au pistolet de 11. Pour obtenir de plus amples renseignements sur la sûreté,
soudage. voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d arc peut être plus sévère qu un coup de soliel, LES MACHINES À SOUDER À
donc:
TRANSFORMATEUR ET À
a. Utiliser un bon masque avec un verre filtrant approprié REDRESSEUR
ainsi qu un verre blanc afin de se protéger les yeux du ray-
onnement de l arc et des projections quand on soude ou
quand on regarde l arc. 1. Relier à la terre le chassis du poste conformement au code de
b. Porter des vêtements convenables afin de protéger la l électricité et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece à souder doit être branché à une
l arc. bonne mise à la terre.
c. Protéger l autre personnel travaillant à proximité au
soudage à l aide d écrans appropriés et non-inflammables. 2. Autant que possible, I installation et l entretien du poste seront
effectués par un électricien qualifié.
4. Des gouttes de laitier en fusion sont émises de l arc de
soudage. Se protéger avec des vêtements de protection libres 3. Avant de faires des travaux à l interieur de poste, la debranch-
de l huile, tels que les gants en cuir, chemise épaisse, pan- er à l interrupteur à la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

®
v v

Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi TABLE OF CONTENTS vi
Page

Installation.......................................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Safety Precautions. ..............................................................................................................A-2
Location and Ventilation ................................................................................................A-2
Storing ...........................................................................................................................A-2
Stacking ........................................................................................................................A-3
Tilting.............................................................................................................................A-3
Lifting.............................................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-3
Oil ..................................................................................................................................A-3
Fuel ...............................................................................................................................A-3
Spark Arrester ...............................................................................................................A-3
Electrical and Welding Connections .....................................................................................A-4
Machine Grounding .......................................................................................................A-5
Plugs and Hand-Held Equipment, Auxiliary Power Receptacles .........................................A-6
Premises Wiring ...................................................................................................................A-6
Circuit Breakers ....................................................................................................................A-6
Electrical Devices used with the Outback™ 185 ..................................................................A-7
________________________________________________________________________________

Operation.........................................................................................................................Section B
Safety Instructions ................................................................................................................B-1
Symbols................................................................................................................................B-2
General Description..............................................................................................................B-3
Recommended Applications.................................................................................................B-3
Operational Features and Controls ......................................................................................B-3
Design Features and Advantages ........................................................................................B-3
Welding Capability................................................................................................................B-3
Limitations ............................................................................................................................B-3
Controls and Settings ...........................................................................................................B-4
Welder/Generator Controls ..................................................................................................B-4
Engine Operation .................................................................................................................B-5
Welding Operation................................................................................................................B-6
Auxiliary Power.....................................................................................................................B-7
Electrode selection Guide .............................................................................................B-7
Auxiliary Power Application ..................................................................................................B-8
________________________________________________________________________________

Accessories .....................................................................................................Section C
General Options / Accessories ..............................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine and Periodic Engine Maintenance....................................................D-1, D-2
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-4
________________________________________________________________________
Wiring Diagram and Dimension Print ............................................................Section F
________________________________________________________________________

Parts List .....................................................................................................P-663 Series

________________________________________________________________________
A-1 INSTALLATION A-1

TECHNICAL SPECIFICATIONS - OUTBACK™ 185 (K2706-2)

INPUT - GASOLINE ENGINE

Make/Model Description Speed (RPM) Displacement Ignition Capacities
System

KOHLER 1 cylinder 3750RPM High Idle 26.2 cu. in Electric & Recoil Fuel: 6.8 gal.
CH440 4 cycle 2250RPM Low Idle (429 cc) Start; (25.7L)
air-cooled 3400RPM Full Load
OHV gasoline Bore x Stroke Manual Oil: 1.2 Qts.
14 HP @ Choke (1.1L)
3600 RPM 3.50” x 2.70”
Aluminum Block (89 mm x 69 mm)
w/ Cast Iron Sleeve

RATED OUTPUT - WELDER

AMPS @ DC CONSTANT CURRENT DUTY CYCLE VOLTS @ RATED AMPERES

100 100% 25
130 60% 25
150 20% 25
185 MAX OUTPUT ---

OUTPUT -WELDER AND GENERATOR

Welding Ranges Welding Open Circuit Voltage AC Auxiliary Power
4600 Watts 115V 1PH
100% Duty Cycle
50 - 185 Amps DC 80 VDC Max. 5700 Peak Watts
5200 Continuous Watts
120 / 230 V 1PH

PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT

25.62 in. 21.77 in. 31.48 in. 295.0 lbs.

651 mm 553 mm 800 mm 133.8 kg

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE

0° F TO 104° F (-18° C TO 40° C) -40° F TO 131° F (-40° C TO 55° C)

OUTBACK™ 185
®
A-2 INSTALLATION A-2

SAFETY PRECAUTIONS LOCATION AND VENTILATION

Read this entire installation section before you Whenever you use the OUTBACK™ 185, be sure that
start installation. clean cooling air can flow around the machine s gasoline
engine and the generator. Avoid dusty, dirty areas. Also,
keep the machine away from heat sources. Do not place the
WARNING back end of the generator anywhere near hot engine
Do not attempt to use this equipment until you exhaust from another machine. And of course, make sure
that engine exhaust is ventilated to an open, outside area.
have thoroughly read all operating and mainte-
nance manuals supplied with your machine. They The OUTBACK™ 185 must be used outdoors. Do not set
include important safety precautions, detailed the machine in puddles or otherwise submerge it in water.
engine starting, operating and maintenance Such practices pose safety hazards and cause improper
operation and corrosion of parts.
instructions, and parts lists.
Hazards of Electric Shock, Engine Always operate the OUTBACK™ 185 with the case roof
Exhaust & Moving Parts on and all machine components completely assembled. This
will help to protect you from the dangers of moving parts,
hot metal surfaces, and live electrical devices.
WARNING
ELECTRIC SHOCK can kill. STORING
• Do not touch electrically live parts
or electrode with skin or wet cloth- 1. Store the machine in a cool, dry place when it is not in
ing. use. Protect it from dust and dirt. Keep it where it can
not be accidentally damaged from construction activi-
• Insulate yourself from work and
ground. ties, moving vehicles and other hazards.
2. If you will be storing the machine for over 30 days, you
• Always wear dry insulating gloves. should drain the fuel to protect fuel system and carbure-
tor parts from gum deposits. Empty all fuel from the
tank and run the engine until it stops from lack of fuel.
ENGINE EXHAUST can kill. 3. You can store the machine for up to 24 months if you
• Use in open, well ventilated areas use a stabilizing Additive in the fuel system. Mix the
or vent exhaust outside. additive with the fuel in the tank and run the engine for
a short time to circulate the additive through the carbu-
• Do not stack anything on or near
the engine. retor.
4. While the engine is still warm, drain the oil and refill with
fresh 10W30 oil.
MOVING PARTS can injure. 5. Remove the spark plug and pour approximately 1/2
ounce (15ml) of engine oil into the cylinder. Replace the
• Do not operate with doors open or
guards off. spark plug and crank the engine slowly to distribute the
oil.
• Stop engine before servicing. 6. Clean any dirt and debris from the cylinder and cylinder
• Keep away from moving parts. head fins and housing, rotating screen, and muffler
areas.
Only qualified personnel should install, use, or 7. Store in a clean, dry area.
service this equipment.

OUTBACK™ 185
®
A-3 INSTALLATION A-3
STACKING OIL
OUTBACK™ 185 machines CANNOT be stacked. The OUTBACK™ 185 is shipped with the engine
filled with SAE 10W30 oil. CHECK THE OIL LEVEL
TILTING BEFORE YOU START THE ENGINE. This is an
added precaution. Do not screw in dipstick when
checking oil level. DO NOT OVERFILL. Be sure the
Place the machine on a secure, level surface whenev-
fill plug is tight after servicing.
er you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound. FUEL
The gasoline engine is designed to run in a level posi- Fill the fuel tank with clean, fresh, regular grade (mini-
tion for best performance. It can operate at an angle, mum 87 octane lead free gasoline. DO NOT MIX OIL
but this should never be more than 15 degrees in any WITH GAS. The OUTBACK™ 185 capacity is approx-
direction. If you do operate it at a slight angle, be sure imately 6.8 gallons (25.74 Liter). DO NOT OVER-
to check the oil regularly and keep the oil level full. FILL, allow room in the fuel tank for fuel expansion.
Also, fuel capacity will be a little less at an angle.
SPARK ARRESTER
LIFTING
Some federal, state or local laws may require gaso-
The OUTBACK™ 185 should be lifted by two people. line engines to be equipped with exhaust spark
(See Specification section for weight). The LowLift™ arresters when they are operated in certain locations
grab bars on both ends make lifting easier. where unarrested sparks may present a fire hazard.
The standard muffler included with this machine
comes equipped with a spark arrester.
PRE-OPERATION ENGINE SERVICE
Read and understand the engine operating and
CAUTION
maintenance instructions supplied with this machine An incorrect additional arrester may lead to dam-
before you operate the OUTBACK™ 185. age to the engine or adversely affect performance.
------------------------------------------------------------------------

WARNING
• Keep hands away from muffler or HOT engine
parts.
• Stop the engine when fueling.
• Do not smoke when fueling.
• Remove fuel cap slowly to release pressure.
• Do not overfill tank.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------

OUTBACK™ 185
®
A-4 INSTALLATION A-4
OUTBACK™ 185 OUTPUT CONNECTIONS
1 4
8 7 5

6
9

10

11

2
FIGURE A.1
1. CURRENT CONTROL DIAL 7. DUPLEX RECEPTACLE (2)- 120 VOLT, 20 AMP
2. WELD OUTPUT TERMINALS (2) 8. HOURMETER
3. GROUND STUD 9. ENGINE SWITCH
4. CIRCUIT BREAKERS (2) - 20 AMP 10. HIGH/AUTO IDLE
5. CIRCUIT BREAKER 30 Amp 11. CHOKE
6. RECEPTACLE - 240 VOLT, 50 AMP

ELECTRICAL OUTPUT CONNECTIONS TABLE A.1

RECOMMENDED WELDING CABLE
See Figure A.1 for the location of the current control SIZE AND LENGTH
dial, weld output terminals, ground stud, circuit break-
ers, 240 and 120 volt receptacles. TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
WELDING CABLE CONNECTIONS Cable 125 Amps
Length 30% Duty Cycle
Cable Size and Length
0-50 ft (0-15m) 6 AWG
Be sure to use welding cables that are large enough.
The correct size and length becomes especially impor- 50-100 ft (15-30 m) 5 AWG
tant when you are welding at a distance from the
welder. 100-150 ft (30-46 m) 3 AWG

Table A.1 lists recommended cable sizes and lengths 150-200 ft (46-61 m) 2 AWG
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the 200-250 ft (61-76m) 1 AWG
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.

OUTBACK™ 185
®
A-5 INSTALLATION A-5
Cable Installation MACHINE GROUNDING
Install the welding cables to your OUTBACK™ 185 as Because this portable engine driven welder or genera-
follows. See Figure A.1 for the location of parts. tor creates its own power, it is not necessary to con-
nect its frame to an earth ground, unless the machine
1. The gasoline engine must be OFF to install weld- is connected to premises wiring (your home, shop,
ing cables. etc.).
2. Remove the 1/2-13 flanged nuts from the output To prevent dangerous electric shock, other equipment
terminals. to which this engine driven welder supplies power,
must:
3. Connect the electrode holder and work cables to a) be grounded to the frame of the welder using a
the weld output terminals. Normally, the electrode grounded type plug
cable is connected to the positive (+) output stud. or
b) be double insulated
4. Tighten the flanged nuts securely.
When this welder is mounted on a truck or trailer, the
5. Be certain that the metal piece you are welding machine grounding stud must be securely con-
(the “work”) is securely connected to the work nected to the metal frame of the vehicle.
clamp and cable.
In general if the machine is to be grounded, it should
6. Check and tighten the connections periodically. be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
CAUTION the ground for at least ten feet and having no insulat-
ed joints, or to the metal framework of a building
• Loose connections will cause the output studs to which has been effectively grounded. The U.S.
National Electrical Code lists a number of alternate
overheat and the studs may eventually melt.
means of grounding electrical equipment. A machine
• Do not cross welding cables at output stud connec- grounding stud marked with the symbol is provid-
ed on the front of the welder.
tion. Keep isolated and separate from one another.
------------------------------------------------------------------------
WARNING
DO NOT GROUND MACHINE TO A PIPE WHICH
Lincoln Electric offers a welding accessory kit with #6
welding cables. See the ACCESSORIES section of CARRIES EXPLOSIVE OR COMBUSTIBLE
this manual for more information. MATERIAL.
------------------------------------------------------------------------
For more information on welding , see WELDING
OPERATION in the OPERATION section of this man-
ual.

OUTBACK™ 185
®
A-6 INSTALLATION A-6
PLUGS AND HAND HELD EQUIPMENT PREMISES WIRING
For further protection against electric shock, any elec- The OUTBACK™ 185 is not recommended for
trical equipment connected to the generator recepta- premises wiring. The OUTBACK™ 185 does not have
cles must use a three-blade, grounded type plug or an a combined 120/240 volt receptacle and cannot be
Underwriter s Laboratories (UL) approved double connected to a premises as described in other Lincoln
insulated tool with a two blade plug. literature.

The OUTBACK™ 185 is intended only for backup,

WARNING intermittent use power. Certain electrical devices can-
not be powered by the OUTBACK™ 185. Refer to
Never operate this machine with damaged or Table A.2 for these devices.
defective cords. All electrical equipment must be
in safe operating condition. CIRCUIT BREAKERS
------------------------------------------------------------------------
AUXILIARY POWER RECEPTACLES Auxiliary power is protected by circuit breakers. When
the machine is operated in high temperature environ-
The control panel of the OUTBACK™ 185 features ments, the breakers may tend to trip at lower loads
three auxiliary power receptacles: than normally.

• Two 20 amp,120 volt duplex (double outlet)

receptacle.
CAUTION
NEVER BYPASS THE CIRCUIT BREAKERS.
• A 50 amp, 240 volt single outlet receptacle.
WITHOUT OVERLOAD PROTECTION, THE UNIT
See Figure A.1 COULD OVERHEAT AND/OR CAUSE DAMAGE TO
THE EQUIPMENT BEING USED.
Through these receptacles the machine can supply up ------------------------------------------------------------------------
to 5700 watts surge or 5200 watts continuous of sin-
gle-phase 60 Hertz AC power. The machine output
voltages meet UL standards and fall within ± 10% of
the rated voltage.

OUTBACK™ 185
®
A-7 INSTALLATION A-7

CAUTION
Certain Electrical devices cannot be powered by the OUTBACK™ 185. See Table A.2

TABLE A.2
ELECTRICAL DEVICE USE WITH THE OUTBACK™ 185

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot
pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capac-
itative elements to fail. Surge
protection, transient protection, and
additional loading is recom-
mended for 100% fail-safe opera-
tion. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting. (See
refrigerators, weed and hedge Table B.3, GENERATOR POWER
trimmers. APPLICATIONS, in the OPERA-
TION section of this manual for
required starting wattages.)
Some synchronous motors may
be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.

Capacitive / Inductive Computers, high resolution TV sets, An inductive type line condition-
complicated electrical equipment. er along with transient and
surge protection is required,
and liabilities still exist.
DO NOT USE THESE DEVICES
WITH A OUTBACK™ 185.

The Lincoln Electric Company is not responsible for any damage to electrical components
improperly connected to a OUTBACK™ 185.

OUTBACK™ 185
®
B-1 OPERATION B-1
SAFETY INSTRUCTIONS
WARNING WARNING
ELECTRIC SHOCK
ENGINE EXHAUST can kill.
can kill.
• Use in open, well ventilated areas
• Do not touch electrically live parts or vent exhaust outside.
or electrode with skin or wet • Do not stack anything on or near
clothing. the engine.

• Insulate yourself from work and

ground. MOVING PARTS can injure.
• Do not operate with doors open or
• Always wear dry insulating guards off.
gloves.
• Stop engine before servicing.
• Keep away from moving parts.
FUMES AND GASES
can be dangerous. Only qualified personnel should install, use, or
service this equipment.
• Keep your head out of fumes.
Observe additional Safety Guidelines detailed
• Use ventilation or exhaust to throughout this manual.
remove fumes from breathing
zone.

WELDING SPARKS
can cause fire or
explosion

• Keep flammable material away.

• Do not weld on containers that

have held combustibles.

ARC RAYS
can burn.

• Wear eye, ear and body

protection.

OUTBACK™ 185
®
B-2 OPERATION B-2

GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL

WARNING / CHOKE
CAUTION

OIL AIR CLEANER

FUEL CIRCUIT
BREAKER

WORK CLAMP GROUND

(AUXILIARY
POWER)

FAST ELECTRODE
WELDING ARC

SLOW ENGINE OFF

AUTO IDLE ENGINE START

OUTBACK™ 185
®
B-3 OPERATION B-3
GENERAL DESCRIPTION DESIGN FEATURES AND
The OUTBACK™ 185 is designed for commercial use
ADVANTAGES
welder/generator applications. As a welder it provides
185 amps of DC constant current for welding with DC • 185 amp DC constant current welding for stick
stick electrodes. A single dial lets you select a full electrodes.
range of welding output from 50 to 185 amps. • Lightweight / portable.
• Full range, continuous welding output control with
As a generator it can supply up to 5700 surge watts or a single knob.
5200 continuous watts of 120 / 240 volt, single-phase • Automatic shutdown under low oil level condition.
AC power. The machine is portable. • Hour Meter Standard.

A Kohler CH440 14 HP air cooled, OHV gasoline • 5700 Surge watts or 5200 Watts of continuous
engine powers the welder / generator. It has an 120 / 240 volt single phase AC auxiliary power.
engine warranty of 3 years. • Kohler CH440 14 HP overhead cam air-cooled
gasoline engine. Smooth running, long life.
RECOMMENDED APPLICATIONS
WELDING CAPABILITY
Welder The OUTBACK™ 185 rated 185 amps, 20 VDC at
The OUTBACK™ 185 provides excellent constant 10% duty cycle on a ten-minute basis. This means
current DC welding output for stick (SMAW) welding. that you can load the welder to 185 amps for one
minute out of every ten-minute period. The machine
Generator is capable of higher duty cycles at lower output cur-
The OUTBACK™ 185 gives smooth AC generator rents. For example, you can load the welder to 100
output for continuous auxiliary power usage within the amps for ten minutes out of ten for a 100% duty cycle.
engine manufacturer s required maintenance recom-
The current is continuously variable from 50 to 185
mendations.
amps DC. The OUTBACK™ 185 can, therefore, weld
with all 3/32”, 1/8” and most 5/32” diameter Lincoln
OPERATIONAL FEATURES AND DC electrodes.
CONTROLS
The OUTBACK™ 185 was designed for simplicity. LIMITATIONS
Therefore, it has very few operating controls. A single
dial on the control panel lets you select either welder • The OUTBACK™ 185 is not recommended for any
or generator use. For welding, the same dial selects processes besides those that are normally per-
continuous current output over the machine s 50 to formed using stick welding (SMAW) procedures.
185 amp range. • The OUTBACK™ 185 is not recommended for
pipe thawing.
The gasoline engine controls include a recoil starter,
choke and stop switch. See ENGINE OPERATION in • During welding, generator power is limited to 100
the OPERATION section of this manual for details watts, and output voltages can drop from 120 to 80
about starting, running, stopping, and breaking in the volts and 240 to 160 volts. Therefore, DO NOT
gasoline engine. OPERATE ANY SENSITIVE ELECTRICAL
EQUIPMENT WHILE YOU ARE WELDING.

OUTBACK™ 185
®
B-4 OPERATION B-4

CONTROLS AND SETTINGS All welder/generator controls are located on the Output Control Panel.
Gasoline engine controls are mounted on the engine. See Figure B.1 and the figures in engine operation section.
OUTPUT PANEL CONTROLS
10 1 9 7 2

8
12

13

11

6 5

3 or 4 FIGURE B.1

WELDER/GENERATOR CONTROLS 10. HOUR METER: Records the time that the engine
See Figure B.1 for the location of the following features: has run for maintenance purposes.
1. CURRENT CONTROL DIAL: Adjusts continuous cur-
11. ENGINE CHOKE: Engine starting aid.
rent output. The amperages on the dial correspond to
the approximate amperages needed for specific
Lincoln welding electrodes. 12. ENGINE SWITCH:
Used to start the engine.
2. 30 AMP CIRCUIT BREAKER: Provide separate over-
load current protection for the 120 Volt and 240 Volt When placed in the “OFF” position, the ignition
Receptacles circuit is de-energized to shut down the engine.
3. WELD POSITIVE OUTPUT TERMINAL: Provides the
connection point for either the electrode holder or the When held in the “START” position, the engine
work cable. (Because the OUTBACK™ 185 is a DC starter motor is energized.
output machine, either output terminal can be used for
either cable.) 13. HIGH/AUTO IDLE: When in “HIGH IDLE” ( )
4. WELD NEGATIVE OUTPUT TERMINAL: Provides the position, the engine will run continuously at high idle.
connection point for either the electrode holder or the
work cable. (Because the OUTBACK™185 is a DC When in “AUTO IDLE” ( / ) position, the
output machine, either output terminal can be used for engine will run continuously and the idler operates as
either cable.) follows:
5. GROUND STUD: Provides a connection point for con-
necting the machine case to earth ground for the • Welding
safest grounding procedure. When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
6. CIRCUIT BREAKER: Provides overload protection for speed. After welding ceases (and no auxiliary power
weld output terminals.
is being drawn), the engine will return to low idle
7. CIRCUIT BREAKERS (2): Provide separate overload after approximately 10 to 14 seconds.
current protection for the 120 volt and 240 volt recepta-
• Auxiliary Power
cles With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately 0-
8. 240 VOLT RECEPTACLE: Connection point for sup-
150 watts or greater) from the receptacles, the
plying 250 volt power to operate one electrical device.
engine will accelerate to high speed. If no power is
9. 120 VOLT DUPLEX RECEPTACLES (2): Connection being drawn from the receptacles (and not welding)
point for supplying 120 volt power to operate devices for 10-14 seconds, the idler reduces the engine
needed for maintenance purposes. speed to low idle.

OUTBACK™ 185
®
B-5 OPERATION B-5
ENGINE OPERATION Break-in Period

Starting/Shutdown Instructions It is normal for any engine to use larger quantities of

oil until break-in is accomplished. Check the oil level
Be sure all Pre-Operation Engine Service has been twice a day during the break-in period (about 50 run-
performed. Also, Read owners manual before starting ning hours). Change the oil after the first 5 hours of
for the first time. (See INSTALLATION section) operation. See the Engine Instruction Manual for fur-
ther details.
Remove all loads connected to the AC power recepta-
cles. Before starting, first open the fuel shutoff valve. CAUTION
Always pull the choke control out when starting the IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE
engine; cold, warm or hot. UNIT SHOULD BE SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF THE MACHINE.
Flip the Idle switch to the “Auto Idle” ( )( ) AVOID LONG IDLE RUNNING PERIODS. REMOVE
position. Lift and hold the start switch in the “start” ( ) LOADS AND ALLOW ENGINE TO COOL SEVERAL
position engine starts. Release the switch to the run MINUTES AT LOW IDLE BEFORE SHUTDOWN.
position and slowly return the choke to the full “In” ------------------------------------------------------------------------
position (Choke open). Do not lift the start switch to Low Oil Sensing
the “start” position while the engine is running
because this will cause damage to the ring gear This engine has a built in sensor which responds to
and/or starter motor. low oil level (not pressure). When activated, the sys-
tem will shut the engine down. The engine will not
Stopping the Engine restart until sufficient oil is added. Check oil level fre-
quently and add oil as required to the full mark on the
Remove all welding and auxiliary power loads and dipstick. DO NOT OVERFILL.
allow engine to run for a few minutes to cool the
engine.
Typical Fuel Consumption
Stop the engine by placing the engine switch in the
“Off” ( ) position.
KOHLER CH440 14 HP

WARNING NO LOAD. .22 GALLONS/HOUR

Close the fuel valve when the machine is 2250 R.P.M .83 ( LITERS/HOUR)
transported to prevent fuel leakage from
NO LOAD .45 GALLONS/HOUR
the carburetor. 3750 R.P.M. (1.70 LITERS/HOUR)
------------------------------------------------------------------------
DC CC WELD OUTPUT .77 GALLONS/HOUR
Fuel Valve is located under the fuel tank and above 100 AMPS, 25 VOLTS (2.92 LITERS/HOUR)
the recoil starter see figure B.2 for “ON/OFF” posi- AUXILIARY POWER 1.09 GALLONS/HOUR
tions. 5200 KVA (4.13 LITERS/HOUR)

FIGURE B.2

OUTBACK™ 185
®
B-6 OPERATION B-6

WELDING OPERATION 4. Insert the electrode into the electrode holder.

5. Set the current control dial to the desired output
current .
WARNING 6. Start the gasoline engine.
ELECTRIC SHOCK can kill. See ENGINE OPERATION in this section of
the manual.
• Do not touch electrically live parts
or electrode with skin or wet cloth- 7. Strike an arc and begin welding.
ing.
AFTER YOU FINISH THE WELD:
• Insulate yourself from work and
ground.
1. Stop the gasoline engine. See ENGINE OPERA-
• Always wear dry insulating gloves.
TION in this section of the manual.
ENGINE EXHAUST can kill. 2. Allow the electrode and work to cool completely.
• Use in open, well ventilated areas 3. Remove the work clamp from the work.
or vent exhaust outside. 4. Remove any remaining piece of electrode from the
• Do not stack anything on or near electrode holder.
the engine. 5. If you are finished using the OUTBACK 185 for weld-
ing, disconnect the welding cables from the weld out-
MOVING PARTS can injure.
put terminals. Reattach the flange nuts and leave
• Do not operate with doors open or them on the terminals.
guards off. For DC+ welding, the electrode cable is to be connected
• Stop engine before servicing. to the “+” output stud and work cable to the “-” output
• Keep away from moving parts. stud. (For DC- welding, reverse these connections.)
Only qualified personnel should install, use, or Semi-automatic Wire Welding with a Lincoln Wire
service this equipment. Feeder/Welder
The OUTBACK™ 185 can deliver from 50 to 185
amps of welding output current . Output can be The OUTBACK™ 185 generator power can be used to
adjusted by setting the current control dial on the out- supply up to 5,200 watts continuous input power to a
put control panel. Lincoln Wire Feeder/Welder. The Wire Feeder/ Welder is
equipped with all the supplies needed for Flux-Cored Arc
You can get maximum welding output by setting the Welding (FCAW). Also some Wire Feeder/Welders come
dial to 185 AMPS. At high current settings like this, equipped with the essentials needed for Gas Metal Arc
some output may decrease as the machine is used. If Welding (GMAW) or MIG processes, while others require
you are welding for a long time, you may need to turn the purchase of a conversion kit. These products are
the dial slightly upward to maintain the same results. available where Lincoln products are sold. Contact your
The numbers on the dial correspond to the approxi- local authorized Lincoln representative for more details.
mate amps needed to weld using specific Lincoln
welding rods. Table B.2, WELDING APPLICATIONS, Plasma Cutting with Lincoln Pro-Cut 25.
give you the recommended dial settings based on the
thickness of the work and the size and type of rod The OUTBACK™ 185 generator power can be used to
you re using. supply up to 5,200 watts continuous input power to a
Pro-Cut 25. The Pro-Cut will work satisfactorily under the
TO USE THE OUTBACK 185 FOR WELDING: following conditions:
1. Remove the flange nuts from the weld output ter-
minals and place the work and electrode welding 1. Set the Current Control on the OUTBACK™ 185 to
cables over the terminals. See Figure B.1 and the 185 amp position. (Higher Settings may result in a
B.1a. Replace and tighten the flange nuts shutdown of the Pro-Cut 25.)
securely. Be sure the connections are tight.
2. Leave the "ON/OFF" switch on the Pro-Cut "OFF"
2. Select the appropriate electrode. See Table B.2 until the OUTBACK 185 has been started and is at full
3. Attach the work clamp securely to the work you are operating speed.
welding.

OUTBACK™ 185
®
B-7 OPERATION B-7

120V Receptacle Operation: Electrical loads in watts are calculated by multiplying

the voltage rating of the load by the number of amps it
• Set the Output Control on the Pro-Cut 25 no higher draws. (This information is given on the load device
than the 15 amp position.( Higher settings may cause nameplate.) For example, a device rated 120 volts, 2
circuit breaker on the OUTBACK™ 185 to trip.) amps will need 240 watts of power (120 x 2 = 240).
• Maximum material thickness that can be cut is 1/4".
You can use Table B.3, AUXILIARY POWER APPLI-
240V Receptacle Operation: CATIONS, to determine the wattage requirements of
the most common types of loads you can power with
• The Pro-Cut 25 may be used for its full range of con- the OUTBACK™ 185 Be sure to read the notes at the
trol. bottom of the table.
• Maximum material thickness that can be cut is 3/8".
TO USE THE OUTBACK 185 AS AN AUXILIARY
POWER SUPPLY:
AUXILIARY POWER OPERATION
1. Start the gasoline engine. See ENGINE OPERA-
TION in this section of the manual.
WARNING
2. Set the current control dial on the output control
Be sure that any electrical equipment plugged into the panel to “MAX.” See Figure B.1.
generator AC power receptacles can withstand a
±10% voltage and a ±5% frequency variation. Some 3. Plug the load(s) into the appropriate 120 volt or
electronic devices cannot be powered by the OUT- 240 volt power receptacle.
BACK 185 Refer to Table A.2, ELECTRICAL DEVICE
USE WITH THE OUTBACK™ 185, in the INSTALLA- NOTE: During welding, the maximum generator output for auxiliary
TION section of this manual. loads is 100 watts.

NOTE: You can supply multiple loads as long as the total load does
GENERAL INFORMATION not exceed 5700 Peak watts or 5200 continuous watts. Be
sure to start the largest loads first.
The OUTBACK™ 185 is rated at 5700 Peak watts or
5200 continuous watts. It provides both 120 volt and
240 volt power. You can draw up to 20 amps from
either side of the 120 volt duplex receptacle, but not
more than 35.4 amps from both sides at once. Up to
17.7 amps can be drawn from the single 240 volt
receptacle.

TABLE B.2
ELECTRODE SELECTION GUIDE
CURRENT RANGE (AMPS)
AWS ELECTRODE
CLASSIFICATION ELECTRODE TYPE POLARITY
3/32 SIZE 1/8 SIZE 5/32 SIZE
E6010 FLEETWELD® 5P DC+ 50-75 75-135 90-175
E6011 FLEETWELD® 35 DC+ 50-75 70-110 80-145
E6011 FLEETWELD® 180 DC+ 50-80 55-110 105-135
E6013 FLEETWELD® 37 DC± 70-95 100-135 145-180
E7018 EXCALIBUR® 7018 DC+ 70-100 90-125 125-185
E7018 JETWELD® LH-73 DC+ 65-85 90-125 130-185
E708-17 & E308L-17 BLUE MAX® 308/308L AC-DC DC+ 50-80 75-110 95-150
ENi-CI SOFTWELD® 99Ni DC+ 50-80 80-110 100-140
- WEARSHIELD® ABR DC+ - 50-150 50-185
1/8 AND
SHEET THICKNESS THINNER 1/8 AND THICKER

OUTBACK™ 185
®
B-8 OPERATION B-8

TABLE B.3
AUXILIARY POWER APPLICATIONS

Suggested Power Applications Running Watts *Start-up Watts

(Continuous) (Peak)

*Air Compressor - 1 HP 2,000 4,000 - 8,000

*Air Compressor - 3/4 HP 1,250 3,100 - 5,000
*Airless Sprayer - 1/3 HP 600 1,500 - 2,400
Chain Saw 1,200
Circular Saw 1,200
Coffee Maker 1,000
*Deep Freezer 500 750 - 2,000
*Electric Motor - 1 HP 1,000 2,500 - 4,000
Electric Range (1 element) 1,500
Electric Skillet 1,250
*Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln Wire Feeder/Welder 4,000

NOTES:
Wattages listed are approximate. Check your equipment for actual wattage.
Equipment with unusually high *START-UP WATTS are listed. For start-up of other equipment that uses
a motor, listed in the table, multiply RUNNING WATTS by 2.
Multiple loads can be used as long as the total load does not exceed 5,700 Peak watts. Be sure to start
the largest loads first.

OUTBACK™ 185
®
C-1 ACCESSORIES C-1

OPTIONS/ACCESSORIES
The following options/accessories are available for
your OUTBACK™185 from your local Lincoln
Distributor:

Accessory Kit (K875) – Includes the following:

• Twenty feet (6.1 meters) of #6 AWG electrode cable

with lug.
• Fifteen feet (4.6 meters) of #6 work cable with lugs.
• Work Clamp
• Headshield with No. 10 filter
• Insulated electrode holder and sample electrodes
150 amp capacity.

Undercarriage (K2722-1) - A two-wheeled, hand

movable undercarriage is available for field installa-
tion.

Rotor Removal Kit (S20925) - A service kit with thru

bolt and impact bolts for removing the generator rotor
from tapered engine crank shaft.

Canvas Cover (K2804-1) - To protect the Outback

185 when not in use. Made from attractive red canvas
which is flame retardant, mildew resistant and water
repellent.

Lift Bail Kit (K2819-1)

Easily installed kit for lifting the machine with a fixed
lifting point.

OUTBACK™ 185
®
D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS OIL: Check the oil level after every 5
hours of operation or daily. BE SURE
TO MAINTAIN THE OIL LEVEL.
WARNING Change the oil the first time after 20 hours of opera-
tion. Then, under normal operating conditions,
• Have qualified personnel do all maintenance and change the oil after every 100 hours or once a year,
troubleshooting work. whichever occurs first. If the engine is operated
under heavy load or in high ambient temperatures,
• Turn the engine off before working inside the
change the oil every 50 hours.
machine.
Drain the oil from the drain plug located on either side
• Remove guards only when necessary to perform
of the engine bottom, as shown in Figure D.1. Refill
maintenance and replace them when the mainte-
through the oil fill plug until the oil reaches the full
nance requiring their removal is complete.
mark on the dip stick. See Engine Owner s manual
• If guards are missing from the machine, get replace- for specific oil recommendations.
ments from a Lincoln Distributor. See the EXPLOD-
ED VIEW AND PARTS LIST at the back of this
FIGURE D.1 - OIL DRAIN AND
manual. REFILL LOCATION
------------------------------------------------------------------------

Read the Safety Precautions in the front of this manu-

al and in the Kohler Operating and Maintenance

OIL
Instructions manual before working on the OUT-
BACK™185 Keep all equipment safety guards, cov-
ers, and devices in position and in good repair. Keep
your hands, hair, clothing, and tools away from the
recoil housing, fans, and all other moving parts when
starting, operating, or repairing this machine.
Do not screw in FILL to FULL mark on
dipstick to check oil dipstick - recheck
ROUTINE AND PERIODIC
MAINTENANCE 12 mm
HEX

ENGINE MAINTENANCE

CAUTION
Drain
plug
To prevent the engine from accidentally starting, dis- OIL DRAIN
PLUG
connect the spark plug lead before servicing the
Tighten dipstick Oil drain
engine. firmly before starting
------------------------------------------------------------------------
See the Kohler Owner s manual for a summary of
maintenance intervals for the engine. Follow either the FUEL: At the end of each day s use, refill
hourly or the calendar intervals, whichever come first. the fuel tank to minimize moisture con-
More frequent service may be required, depending on densation and dirt contamination in the
your specific application and operating conditions. The fuel line.
Kohler Owner s manual shows engine maintenance AIR CLEANER: With normal operating
replacement parts and numbers. conditions, the maintenance schedule for
cleaning and re-oiling the foam pre-filter
is every 50 hours and replacement of the
air cleaner filter element every 100 hours.
More frequent servicing is required with dusty operat-
ing conditions. Refer to the maintenance section of
the Engine Owner s Manual for more information.

OUTBACK™ 185
®
D-2 MAINTENANCE D-2
To service the pre-cleaner:
Remove the cover. Carefully remove the foam pre-
WARNING
cleaner from the filter element. ENGINE ADJUSTMENTS
1. Wash in liquid detergent and water. OVERSPEED IS HAZARDOUS - The maximum
allowable high idle speed for this machine is 3750
2. Squeeze dry in a clean cloth.
RPM, no load. Do NOT tamper with the governor
3. Saturate in clean engine oil. components or setting or make any other
adjustments to increase the maximum speed.
4. Squeeze in a clean, absorbent cloth to remove all
Severe personal injury and damage to the
excess oil.
machine can result if operated at speeds above
Carefully place the pre-cleaner back over the filter ele- maximum.
ment and reinstall the air cleaner cover and wing nuts. ------------------------------------------------------------------------
Adjustments to the engine are to be made only by a
CLEAN ENGINE: Remove dirt and debris with a cloth
Lincoln Service Center or an authorize Field Service
or a brush. Do not clean with a forceful spray of
Shop.
water. Water might contaminate the fuel system. Use
low pressure air to blow out the machine periodically.
In particularly dirty locations this may be required SLIP RINGS
once a week.
SPARK PLUG SERVICE CAUTION
The Spark plug can be serviced by either of the fol-
lowing methods: See Figure D.2. A slight amount of darkening and wear of the slip
rings and brushes is normal. Brushes should be
FIGURE D.2 inspected when a general overhaul is necessary.
METHOD 2 If brushes are to be replace, clean slip rings with a
fine emery paper.
Do not attempt to polish slip rings while engine is
running.
------------------------------------------------------------------------
HARDWARE
METHOD 1
Both English and Metric fasteners are used in this
welder.

Spark Plug
Location
ENGINE MAINTENANCE PARTS
Roof and Panel
Removed
Kohler CH440

Spark Plug Air Filter Element 63 083 19-S

Location
Air Filter Pre-Cleaner 63 083 17-S
Spark Plug Champion RC 12YC
1. Access Spark Plug by reaching underneath the side (Resistor Type) (Gap .030” [.76mm])
panel near the muffler.
2. Remove 20 screws securing the roof, and side
panel to gain access to the Spark Plug. Be sure to
OPERATIONAL CLEARANCE
support the fuel tank tray and control panel once
the side panel is removed.
CAUTION
CAUTION Approximately 12-18” of clearance should be
around this unit during operation for air flow.
• Be sure not to cross thread Spark Plug when Reducing this clearance will reduce air flow to the
reinstalling. machine causing operational temperatures to
• This area is HOT if engine has been running. increase. Possible damage to the machine can
Allow engine to cool before servicing. result if to much air flow is restricted.
------------------------------------------------------------------------ ------------------------------------------------------------------------

OUTBACK™ 185
®
E-1 TROUBLESHOOTING E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

OUTBACK™ 185
®
E-2 TROUBLESHOOTING E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS

Major Physical or Electrical 1. Contact your local Lincoln

Damage is Evident. Authorized Field Service Facility.

No Generator power or welding 1. Check brushes for wear. See

output Maintenance section.
2. Check for loose or faulty
connections at brush holders.
3. Open lead in flashing or field
circuit.
4. Rheostat (R1) lead broke.
5. Dirty slip rings. If all recommended possible areas
6. Faulty rheostat (R1). of misadjustment have been
7. Faulty field bridge rectifier (D1). checked and the problem persists,
8. Faulty field capacitor (C1). Contact your local Lincoln
9. Faulty stator field winding. Authorized Field Service Facility.
10. Faulty rotor.

Generator power is available 1. Loose connector to output stud.

but unit will not weld. 2. Work not connected.
3. Electrode holder loose.
4. No open circuit voltage at output
studs. Open lead in weld circuit.
5. Faulty output bridge rectifier.
6. Faulty choke (L1).

Unit will weld but low or no 1. Circuit breaker is open.

generator power is available. 2. Loose or open connection with
electrical plug-in component.
3. Current control dial not at “MAX”
4. No open circuit voltage at
receptacle.

No auxillary power but machine has 1. Check CB1 and CB2 - Reset if
weld output. tripped.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
OUTBACK™ 185
®
E-3 TROUBLESHOOTING E-3
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE RECOMMENDED

(SYMPTOMS) CAUSE COURSE OF ACTION
ENGINE PROBLEMS
Engine will not idle down to low 1. Engine Switch on HIGH Idle.
2. Engine choke is not fully open.
speed.
3. External load on welder or
auxiliary power. - Remove load.
4. Machine output is under load or
Engine switch in wrong position.
5. Idle solenoid does not pull in.
Engine idles down to low idle but 1. Engine low idle RPM may be set
will not stay at low idle. too low. - Contact Lincoln Field
Service Facility.
1. Check Work and Electrode
Engine will not go to high idle when
cables for loose or faulty con-
attempting to weld or use generator If all recommended possible areas
nections.
power. of misadjustment have been
2. Mechanical linkage from sole-
noid to engine stuck. checked and the problem persists,
3. Open connection in weld circuit. Contact your local Lincoln
4. No output from receptacles or Authorized Field Service Facility.
load too small.
5. Idler pc board is not sensing
output current.
6. Faulty idler pc board.
Engine will not go to high idle when 1. Auxiliary load less than 100
using auxiliary power. watts.
2. Circuit breaker CB1 or CB2
tripped or faulty.
3. Mechanical linkage from sole-
noid to engine stuck.
Engine runs erratic or stops running 1. Oil level may be low activating
or engine surges at low idle. the engine “Oil Gard” shutdown
system. - Check oil level.
2. Idle solenoid linkage or engine
idle misadjusted.
Recoil starter is hard to pull. 1. Crankcase may be over-filled
with oil. - Check oil level.

1. Water in engine from rain and / or

Engine will not start or starts but
runs rough with low power. condensation. - Remove spark
plug and dry it if wet. Blow low
pressure compressed air in spark
plug port while pulling recoil starter.
Re-install spark plug.
2. Spark plug may be faulty.
3. Air filter element saturated with
water and / or oil - Replace.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
OUTBACK™ 185
®
E-4 TROUBLESHOOTING E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
WELDING PROBLEMS

Engine runs erratically or stops 1. Engine is not fully warmed-up

running. and engine choke is in the fully
open (RUN) position.
2. Engine requires service to head,
carburetor, filters, oil spark plug
and / or gas.
3. Oil level to low.

Engine sputters but will not start. 1. Bad gas, bad filter, air cleaner,
spark plug, and / or breather.

Recoil starter is hard to pull. 1. Too much oil in crankcase.

Arc is erratic and “pops out”. 1. Check Work and Electrode

cables for loose or faulty If all recommended possible areas of
connection. misadjustment have been checked
and the problem persists, Contact
2. Electrode may be wet. your local Lincoln Authorized
Field Service Facility.

Arc becomes “Cold” at the short Arc 1. Reset circuit breaker (CB4)
lenghts or shorts to the work piece. located under the Current
Control Dial on the bottom side
of the control panel.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
OUTBACK™ 185
®
 F-1

®
DIAGRAMS

OUTBACK™ 185
ENHANCED DIAGRAM

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
 F-2

NOTES:
N.A. CENTER OF GRAVITY WITH OIL IN ENGINE
AND EMPTY FUEL TANK.

17.50

.41 HOLE
(4 PLACES) 14.17 7.30

BOTTOM VIEW

®
OUTBACK™ 185
DIMENSION PRINT

N.A.
25.62

10.75

14.00
21.77 31.48
A.02

M22561
F-2
 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection.
electrode with skin or wet clothing.
WARNING Insulate yourself from work and
ground.
Spanish
No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION Aislese del trabajo y de la tierra.

French Ne laissez ni la peau ni des vête- Gardez à l’écart de tout matériel Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
Isolez-vous du travail et de la terre.

German Berühren Sie keine stromführenden Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
Não toque partes elétricas e elec- Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or
Use ventilation or exhaust to guards off.
remove fumes from breathing zone. WARNING
Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o Spanish
piración.
Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
Gardez la tête à l’écart des fumées. Débranchez le courant avant l’entre- N’opérez pas avec les panneaux French
Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
Vermeiden Sie das Einatmen von Strom vor Wartungsarbeiten Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
Mantenha seu rosto da fumaça. Não opere com as tampas removidas. Mantenha-se afastado das partes
Use ventilação e exhaustão para Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. Não opere com os paineis abertos ATENÇÃO
Não toque as partes elétricas nuas. ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
 Need Help?
Lincoln Electric “Rapid Response” Service!
Call 1.888.935.3877 to talk to a Service Representative
Hours of Operation: 8:00 A.M. to 6:00 P.M. (ET) Mon. thru Fri.

After hours? Use “Ask the Experts” at lincolnelectric.com

A Lincoln Service Representative will contact you by the next business day.

• For Non-U.S. Service: Email [email protected]

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.216.481.8100 For Service in U.S. and Canada: Call 1.888.935.3877
FAX: 1.216.486.1751 WEB SITE: lincolnelectric.com For Non-U.S. Service: Email [email protected]